Disclosed is a method which may include providing a battery cell sensing application specific integrated circuit comprising at least a first channel and a second channel, a first connection line connected to the first channel and a second connection line connected to the second channel, a first weld pad connected to the first connection line, a second weld pad connected to the second connection line, and binding a first shunt to the first weld pad and the second weld pad.
Legal claims defining the scope of protection, as filed with the USPTO.
. A method comprising:
. The method as set forth inwherein the battery cell sensing application specific integrated circuit further comprises a third channel and a fourth channel, a third connection line connected the third channel, a fourth connection line connected to the fourth channel, third weld pad connected to the third connection line, and fourth weld pad connected to the fourth connection line; and
. The method as set forth infurther comprising a first extension comprising a first flexible circuit including a first sense line trace.
. The method as set forth infurther comprising connecting a first wire bond to the first sense line trace and to the first shunt.
. The method as set forth infurther comprising connecting a first wire bond to the first weld pad and the first connection line, and connecting a second wire bond to the second weld pad and the second connection line.
. The method as set forth inwherein the battery cell sensing application specific integrated circuit comprising a third channel and a fourth channel, a third connection line connected to the third channel and a fourth connection line connected to the fourth channel, a third weld pad connected to the fourth connection line and a fourth weld pad connected to the fourth connection line; and
. The method as set forth infurther comprising a second extension comprising a second flexible circuit including a second sense line trace.
. The method as set forth infurther comprising connecting a second wire bond to the second sense line trace and to a second shunt.
. The method as set forth infurther comprising connecting a third wire bond to the third weld pad and the third connection line, and connecting a fourth wire bond to the fourth weld pad and the fourth connection line.
. The method as set forth inwherein the battery cell sensing application specific integrated circuit further comprising at least a third channel, a third connection line connected to a third weld pad, a second sense line trace connected to a second cell or cell group; and
. The method as set forth inwherein the battery cell sensing application specific integrated circuit further comprising at least a fifth channel, a fifth connection line connected to a fifth weld pad; and
. A method comprising:
. The method as set forth infurther comprising changing the first circuit configuration of the second modular component comprising connecting the first shunt to the first weld pad, the second weld, and the third weld pad of the second modular component.
. The method as set forth incomprising leaving the first circuit configuration of the third modular component unchanged.
. The method as set forth inwherein the battery cell sensing application specific integrated circuit further comprises a fourth channel, a fifth channel, and a sixth channel, a fourth connection line connected and the fourth channel and a fourth weld pad, a fifth connection line connected to the fifth channel and a fifth weld pad, and a sixth connection line connected to the sixth channel and to a sixth weld pad; and
. The method as set forth infurther comprising a first extension comprising a first flexible circuit including a first sense line trace and a second sense line trace connected to a first cell or cell group.
. The method as set forth infurther comprising connecting a first wire bond to the first sense line trace and to the first shunt, and connecting a second wire bond to the second sense line trace and to the first shunt.
. The method as set forth infurther comprising a second extension comprising a second flexible circuit including a third sense line trace and a fourth sense line trace connected to a second cell or cell group.
. The method as set forth infurther comprising connecting a second wire bond to the third sense line trace and to the second shunt.
. A product comprising:
Complete technical specification and implementation details from the patent document.
The technical field generally relates battery, components thereof and methods of making the same.
Batteries have heretofore utilized the mechanical connector for connecting sense line assemblies together.
It is desirable to provide a design and method of manufacturing batteries without utilizing a mechanical connector for connecting sense line assemblies together. Furthermore, other desirable features and characteristics of the variations disclosed herein will become apparent from the subsequent detailed description and the appended claims, taken in conjunction with the accompanying drawings and the foregoing.
A number of variations may include a method including: providing a battery cell sensing application specific integrated circuit including at least a first channel and a second channel, a first connection line connected to the first channel, a second connection line connected to the second channel, a first weld pad connected to the first connection line and a second weld pad connected to the second connection line; and welding a first shunt to the first weld pad and the second weld pad.
A number of variations may include a method wherein the battery cell sensing application specific integrated circuit further includes a third channel and a fourth channel, a third connection line connected the third channel, a fourth connection line connected to the fourth channel, third weld pad connected to the third connection line, and fourth weld pad connected to the fourth connection line; and welding a second shunt to the third weld pad and fourth weld pad.
A number of variations may include a method further including a first extension including a first flexible circuit including a first sense line trace.
A number of variations may include a method further including connecting a first wire bond to the first sense line trace and to the first shunt.
A number of variations may include a method further including connecting a first wire bond to the first weld pad and the first connection line, and connecting a second wire bond to the second weld pad and the second connection line.
A number of variations may include a method wherein the battery cell sensing application specific integrated circuit including a third channel and a fourth channel, a third connection line connected to the third channel and a fourth connection line connected to the fourth channel, a third weld pad connected to the fourth connection line and a fourth weld pad connected to the fourth connection line; and welding a second shunt to the third weld pad and the fourth weld pad.
A number of variations may include a method further including a second extension including a second flexible circuit including a second sense line trace.
A number of variations may include a method further including connecting a second wire bond to the second sense line trace and to a second shunt.
A number of variations may include a method further including connecting a third wire bond to the third weld pad and the third connection line, and connecting a fourth wire bond to the fourth weld pad and the fourth connection line.
A number of variations may include a method wherein the battery cell sensing application specific integrated circuit further including at least a third channel, a third connection line connected to a third weld pad, a second sense line trace connected to a second cell or cell group; and further including welding the first shunt to the third weld pad.
A number of variations may include a method wherein the battery cell sensing application specific integrated circuit further including at least a fifth channel, a fifth connection line connected to a fifth weld pad; and further including welding the second shunt to the fifth weld pad.
A number of variations may include a method including: providing at least a first modular component, a second modular component, and a third modular component wherein each the first modular component, the second modular component, and the third modular component includes a battery cell sensing application specific integrated circuit including at least a first channel, a second channel, and a third channel, a first connection line connected to the first channel, a second connection line connected to the second channel, a third connection line connected to the third channel, a first weld pad connected to the first connection line, a second weld pad connected to the second connection line, a third weld pad connected to the third connection line, wherein both of the first modular component, the second modular component, and the third modular component each have a first circuit configuration; and changing the first circuit configuration of the first modular component including connecting a first shunt to at least the first weld pad and the second weld pad of the first modular component.
A number of variations may include a method further including changing the first circuit configuration of the second modular component including connecting the first shunt to the first weld pad, the second weld, and the third weld pad of the second modular component.
A number of variations may include a method including leaving the first circuit configuration of the third modular component unchanged.
A number of variations may include a method wherein the battery cell sensing application specific integrated circuit further includes a fourth channel, a fifth channel, and a sixth channel, a fourth connection line connected and the fourth channel and a fourth weld pad, a fifth connection line connected to the fifth channel and a fifth weld pad, and a sixth connection line connected to the sixth channel and to a sixth weld pad; and welding a second shunt to at least the fourth weld pad and fifth weld pad.
A number of variations may include a method further including a first extension including a first flexible circuit including a first sense line trace and a second sense line trace connected to a first cell or cell group.
A number of variations may include a method further including connecting a first wire bond to the first sense line trace and to the first shunt, and connecting a second wire bond to the second sense line trace and to the first shunt.
A number of variations may include a method further including a second extension including a second flexible circuit including a third sense line trace and a fourth sense line trace connected to a second cell or cell group.
A number of variations may include a method further including connecting a second wire bond to the third sense line trace and to the second shunt.
A number of variations may include a product including: a battery cell sensing application specific integrated circuit including at least a first channel and a second channel, a first connection line connected to the first channel and a second connection line connected to the second channel, a first weld pad connected to the first connection line and a second weld pad connected to the second connection line; and a first shunt welded to the first weld pad and the second weld pad.
The following detailed description is merely illustrative in nature and is not intended to limit the application and uses. Furthermore, there is no intention to be bound by any expressed or implied theory presented in the preceding introduction, brief description of the drawings, and summary or the following detailed description.
A plurality of sense lines, which are low current traces between cells and a battery management system, may be utilized to manage a battery cell or group of cells in a battery. When one or more cells are at a peak voltage, and other cells are lower, a relay may close to discharge the peak voltage cell (or group of cells) through a balancing resistor. This will reduce the voltage to match the next highest voltage cell.
A number of variations are illustrated in, which may include a productwhich may be a portion of a battery management system and may include a plurality of battery cells or cell groups including a first cell or cell group, a second cell or cell group, third cell or cell groupand so on. The first cell or cell groupmay include a first terminalwhich may be a positive terminal, and a second terminalwhich may be a negative terminal. Similarly, the second cell or cell groupmay include a first terminalwhich may be a positive terminal and a second terminalwhich may be a negative terminal, and the or cell groupmay include a first terminalwhich may be a positive terminal and a second terminalwhich may be a negative terminal. A busbarmay include a plurality of portions connected to each cell or cell group, respectively. In a number of variations, a first portionof the busbarmay be connected to the first terminalof the first cell or cell group. A second portionof the busbarmay be connected to the second terminalof the first cell or cell groupand to the first terminalof the second cell or cell group. Similarly, third portionof the busbarmay be connected to the second terminalof the second cell or group and to the first terminalof the third cell or cell group. The busbarmay include a fourth portionthat may be connected to the second terminalof the third cell or cell group.
A first sense linemay be connected to the first portionof the busbarand a second sense linemay be connected to the second portionof the busbar. The first sense lineand the second sense linemay be selectively connected together by a first relayand a first balancing resistorpositioned to operate when the first relaycloses. A third sense linemay be connected to the third portionof the busbar. The third sense lineand the second sense linemay be selectively connected together by a second relayand a second balancing resistorpositioned to operate when the second relaycloses. A fourth sense linemay be connected to the to the fourth portionof the busbar. The fourth sense lineand the third sense linemay be selectively connected together by a third relayand a third balancing resistorpositioned to operate when the third relaycloses.
illustrates a number of variations, which may include a productwhich may include a battery management system cell sensing devicewhich may include a cell sensing application specific integrated circuit (ASIC). The cell sensing ASICmay include a plurality of channels for sense lines to connect to including, for example an ASIC ground channeland an ASIC power channel. A plurality of other channels may be provided, for example, channel 0 illustrated by reference, channel 1 illustrated by reference, channel N illustrated by reference, channel N-1 illustrated by reference, and a plurality of other channels, for example, a first channeland a second channel.
A sense line interconnection devicemay be provided and may include a plurality of interconnection lines or pathways. A first connection linemay be connected to the ASIC ground channeland to first weld pad. A second connection linemay be connected to channel 0 indicated by referenceand to a second weld pad. A third connection linemay be connected to channel 1 indicated by referenceand to third weld pad. A fourth connection linemay be connected to the first channeland to a fourth weld pad. A fifth connection linemay be connected to the second channeland to a fifth weld pad. A sixth connection linemay be connected to channel N-1and to a sixth weld pad. A seventh connection linemay be connected to channel Nand to a seventh weld pad. And an eighth connection linemay be connected to the ASIC power channel and to an eighth weld pad.
In a similar manner as illustrated in, a plurality sense line traces may be connected to terminals of a cell or group of cells. For example, a first sense line tracemay be directly or indirectly connected to the second weld padand a first cell or cell group. A second sense line tracemay be directly or indirectly connected to the third weld padand to the first cell or cell groupand to a second cell or cell group. A third sense line tracemay be directly or indirectly connected to the fourth weld padand to the second cell or cell groupand to a third cell or cell group. A fourth sense line tracemay be directly or indirectly connected to the fifth weld padand to the third cell or cell groupand to a fourth cell or cell group. A fifth sense line tracemay be directly or indirectly connected to the sixth weld padand to the fourth cell or cell groupand to a fifth cell or cell group. A sixth sense line tracemay be directly or indirectly connected to the seventh weld padand to the fifth cell or cell group. A first shuntmay be connected to the first weld pad, the second weld pad, and the third weld pad. Adding the first shuntresult in the first cell or cell group being unpopulated and is ignored in cell balancing by the battery management system. A second shuntmay be connected to the eighth weld pad, the seventh weld pad, and the sixth weld pad. Adding the second shuntresults in the fifth cell or cell group being unpopulated and is ignored in cell balancing by the battery management system. A relay and balancing resistor may be provided and selectively connected to two sense lines, for example as illustrated in, for each cell of cell group.
A number of variations are illustrated in, which may be similarly constructed as illustrated inexcept that a sense line interconnect device is not provided, and the first shuntmay be connected to the first weld padand the second weld padto short together the ASIC power channeland the channel 0. The second shuntmay be connected to the eighth weld padand the seventh weld padto short together the ASIC power channeland the channel N, and. As will be appreciated from the variations illustrated inat least one shunt may be used to short at least two weld pads together and/or to unpopulated at least one cell or cell group.
A number of variations are illustrated in, which may a first modular component which may include a central integrated circuit board and sense line assemblywhich may include the battery management system cell sensing device, the cell sensing ASIC, a plurality of connection lines, a plurality of weld pads, and/or web plurality of sense lines. At least one extension, for example, a first extensionand/or a second extensionmay be provided. The first extensionand/or the second extensionmay be positioned in the same plane as the central integrated circuit board and sense line assembly, or at least a portion of the first extensionand/or the second extensionmay overlie the central integrated circuit board and sense line assembly. The first extensionand/or the second extensionmay include at least one sense line, or the at least one shunt or at least one shunt may be provided as a separate piece.
The cell sensing ASICmay include a plurality of channels for sense lines to connect to including, for example an ASIC ground channeland an ASIC power channel. A plurality of other channels may be provided, for example, channel 0 illustrated by reference, channel 1 illustrated by reference, channel N illustrated by reference, channel N-1 illustrated by reference, and a plurality of other channels, for example, a first channeland a second channel.
A first connection linemay be connected to the ASIC ground channeland to first weld pad. A second connection linemay be connected to channel 0 indicated by referenceand to a second weld pad. A third connection linemay be connected to channel 1 indicated by referenceand to third weld pad. A fourth connection linemay be connected to the first channelinto fourth weld pad. A fifth connection linemay be connected to the second channeland to a fifth weld pad. A sixth connection linemay be connected to channel N-1and to a sixth weld pad. A seventh connection linemay be connected to channel Nand to a seventh weld pad. And an eighth connection linemay be connected to the ASIC power channel and to an eighth weld pad.
In a similar manner as illustrated in, a plurality sense lines may be connected to terminals of a cell or group of cells. The first extensionmay include a first sense line tracewhich may be directly or indirectly connected to the second weld pador the first shunt, and a first cell or cell group. A second sense line tracemay be directly or indirectly connected to the third weld padand to the first cell or cell groupand to a second cell or cell group. A third sense line tracemay be directly or indirectly connected to the fourth weld padand to the second cell or cell groupand to a third cell or cell group. A fourth sense line tracemay be directly or indirectly connected to the fifth weld padand to the third cell or cell groupand to a fourth cell or cell group. A fifth sense line tracemay be directly or indirectly connected to the sixth weld padand to the fourth cell or cell groupand to a fifth cell or cell group. The second extensionmay include a sixth connection line tracewhich may be directly or indirectly connected to the seventh weld pador to the second shunt, and to the fifth cell or cell group. A first shuntmay be connected to the first weld pad, the second weld pad, and the third weld pad. Adding the first shuntresult in the first cell or cell group being unpopulated and is ignored in cell balancing by the battery management system. A second shuntmay be connected to the eighth weld pad, the seventh weld pad, and the sixth weld pad. Adding the second shuntresults in the fifth cell or cell group being unpopulated and is ignored in cell balancing by the battery management system. A relay and balancing resistor may be provided and selectively connected to two sense lines, for example as illustrated in, for each cell of cell group.
A number of variations are illustrated in, which may be similarly constructed as illustrated inexcept that the second shuntmay be connected to the eighth weld padand the seventh weld padto short together the ASIC power channeland the channel N, and the first shuntmay be connected to the first weld padand the second weld padto short together the ASIC power channeland the channel. As will be appreciated from the variations illustrated inat least one shunt may be used to short at least two weld pads together and/or to unpopulated at least one cell or cell group.
A number of variations are illustrated in, which may include a productwhich may include a first extensionwhich may include a first sense line traceconnected to a first shuntby a first wire bond. The first sense line tracemay be carried or enclosed in a first polymeric material, for example, a polyamide. The first sense line traceand the first polymeric materialmay form a first flexible circuit. The first polymeric materialand the first sense line tracemay be supported by a first substrate, which may be a nonconductive substrate such as a fiberglass board. A first modular component may be a central integrated circuit board and sense line assemblymay include a first connection linewhich may be carried by or enclosed by a second polymeric material. The first connection linemay be connected to a first weld padby a second wire bond. A first shuntmay be welded to a first weld padand a first connection lineconnected to the first weld padby a second wire bond. The first weld padmay be a part of the central integrated circuit board and sense line assemblymay be a separate piece.
Clause 1. A method comprising: providing a battery cell sensing application specific integrated circuit comprising at least a first channel and a second channel, a first connection line connected to the first channel, a second connection line connected to the second channel, a first weld pad connected to the first connection line and a second weld pad connected to the second connection line; and welding a first shunt to the first weld pad and the second weld pad.
Clause 2. The method as set forth in clause 1 wherein the battery cell sensing application specific integrated circuit further comprises a third channel and a fourth channel, a third connection line connected the third channel, the fourth connection line connected to fourth channel, third weld pad connected to the third connection line, and fourth weld pad connected to the fourth connection line; and welding a second shunt to the third weld pad and fourth weld pad.
Clause 3. A method as set forth in clause 1 further comprising a first extension comprising a first flexible circuit including a first sense line trace.
Clause 4. A method as set forth in clause 3 further comprising connecting a first wire bond to the first sense line trace and to the first shunt.
Clause 5. A method as set forth in clause 1 further comprising connecting a first wire bond to the first weld pad and the first connection line, and connecting a second wire bond to the second weld pad and the second connection line.
Clause 6. A method as set forth in clause 3 wherein the battery cell sensing application specific integrated circuit comprising a third channel and a fourth channel, a third connection line connected to the third channel and a fourth connection line connected to the fourth channel, a third weld pad connected to the fourth connection line and a fourth weld pad connected to the fourth connection line; and welding a second shunt to the third weld pad and the fourth weld pad.
Clause 7. A method as set forth in clause 6 further comprising a second extension comprising a second flexible circuit including a second sense line trace.
Clause 8. A method as set forth in clause 7 further comprising connecting a second wire bond to the second sense line trace and to a second shunt.
Clause 9. A method as set forth in clause 8 further comprising connecting a third wire bond to the third weld pad and the third connection line, and connecting a fourth wire bond to the fourth weld pad and the fourth connection line.
Clause 10. A method as set forth in clause 1 wherein the battery cell sensing application specific integrated circuit further comprising at least a third channel, a third connection line connected to a third weld pad, a second sense line trace connected to a second cell or cell group; and further comprising welding the first shunt to the third weld pad.
Clause 11. A method as set forth in clause 6 wherein the battery cell sensing application specific integrated circuit further comprising at least a fifth channel, a fifth connection line connected to a fifth weld pad; and further comprising welding the second shunt to the fifth weld pad.
Clause 12. A method comprising: providing at least a first modular component, a second modular component, and a third modular component wherein each the first modular component, the second modular component, and the third modular component comprises a battery cell sensing application specific integrated circuit comprising at least a first channel, a second channel, and a third channel, a first connection line connected to the first channel, a second connection line connected to the second channel, a third connection line connected to the third channel, a first weld pad connected to the first connection line, a second weld pad connected to the second connection line, a third weld pad connected to the third connection line, wherein both of the first modular component, the second modular component, and the third modular component each have a first circuit configuration; and changing the first circuit configuration of the first modular component comprising connecting a first shunt to at least the first weld pad and the second weld pad of the first modular component.
Clause 13. A method as set forth in clause 12 further comprising changing the first circuit configuration of the second modular component comprising connecting the first shunt to the first weld pad, the second weld, and the third weld pad of the second modular component.
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November 13, 2025
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